Safety Recall 20TA03 Incomplete Or Nondeployment Of Airbags And/or Seat Belt Pretensioners May Occur – 2012 Toyota Avalon

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TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20TA03
INCOMPLETE OR NONDEPLOYMENT OF AIRBAGS AND/OR SEAT BELT PRETENSIONERS MAY OCCUR
CERTAIN
2012 AVALON
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this recall repair are required to currently hold at least one of the following certification levels:
• Expert (Electrical or Hybrid)
• Master
• Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times.
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OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps as outlined in the full technical instructions to confirm the campaign is completed correctly.
CoveredCampaign completed, return the vehicle to the customerVerify Vehicle Eligibility1. Confirm vehicle VIN matches the R.O.2. Check the TIS Vehicle Inquiry SystemNot CoveredNo further action requiredInstall the Airbag Sub HarnessComplete the Post Quality Repair check sheetPerform Health check and record any DTCs
IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
NOTE:
• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the campaign has not already been completed prior to dealer shipment or by another dealer.
• TMNA warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were completed by another dealer.
PREPARATION
A. PARTS
Part Number
Part Description
Quantity
04009-98112
Airbag Harness Kit*
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* The kit above includes the following parts:
Part Number
Part Description
Quantity
82821-12C30
Urethane Sheet
1
89171-12020
Airbag Sub Harness
1
89279-12180
Water Guard Sheet
5.91in. (150mm) x 5.91in.(150mm)
1
89279-12190
Water Guard Sheet
4.72in. (120mm) x 5.91in. (150mm)
1
89279-12200
Water Guard Sheet
3.15in. (80mm) x 3.94in.(100mm)
1
89639-12020**
Cable Tie
7
90980-12878
Connector Holder
1
**: NOT required to use all the cable ties.
B. TOOLS & EQUIPMENT
• Standard Hand Tools
• Techstream
• Work Gloves
• Molding Remover
C. MATERIALS
• Protective Tape
• Marker pen
• Vinyl Tape
WORK PROCEDURE TABLE OF CONTENTS
SAFETY PRECAUTIONS ················································································· SECTION V.
INSTALL AIRBAG SUB HARNESS····································································· SECTION VI.
APPENDIX ···································································································· SECTION VII.
SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY
Always remember “SAFETY FIRST”.
1. TAKE PREVENTIVE MEASURES AGAINST INJURY
a) Wear gloves so as not to get injured by burrs etc. on the instrument panel reinforcement and the bracket.
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INSTALL AIRBAG SUB HARNESS
COMPONENTS
1. PERFORM HEALTH CHECK
1. Using a Techstream, perform a Health Check and record any DTCs found.
NOTE: A Health check must be performed on every vehicle. Record any DTCs as they are used to confirm the vehicles final state after repair and aid in any additional discussions needed with the customer
2. DISCONNECT THE NEGATIVE BATTERY CABLE
• Wait at least 90 seconds after disconnecting the cable from the negative battery terminal to prevent airbag and seat belt pretensioner deployment.
• Follow all precautions as outlined on TIS before servicing the SRS system.
3. DISCONNECT THE CONNECTOR OF THE AIRBAG SENSOR ASSEMBLY
Click the link below to access TIS for instructions
SUPPLEMENTAL RESTRAINT SYSTEMS: CENTER AIRBAG SENSOR ASSEMBLY: REMOVAL
(Doc ID: RM000000UWV06WX)
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4. PREPARE AIRBAG SUB HARNESS
Click the play button to watch a video on how to prepare the airbag sub harness
NOTE: The video may take several minutes to load depending on internet connection.
IMPORTANT
The procedure shown in these technical instructions is for 2012 AVALON only. DO NOT use it for other vehicle models.
Install each water guard sheet properly
There are 3 different water guard sheets which will be used to protect the airbag sub harness. Each water guard sheet has double-sided tape on a side. If you install a sheet at a wrong position and seal with the tape, the sheet will no longer be reusable. Please make sure to follow the instructions on these Technical Instructions and install each sheet at correct positions.
Handling of airbag sub harness
• DO NOT twist the airbag sub harness forcibly as it may be damaged.
• DO NOT touch the terminals of the link connector. Also, make sure that no foreign matter enters the terminals of the link connector.
a) Before starting the work, place the airbag sub harness following the instructions below to ensure you are dealing with it at the proper orientation.
(1) Place the module and link connector to the right side seen from you.
(2) Place the connector (30P) to the left side seen from you.
b) Remove the plastic bag.
Ensure the urethane sheet is flush with the connector in the next step.
c) Wrap the urethane sheet (7.87in. (200mm) x 1.97in. (50mm)) around the link connector.
d) Press the position shown in the illustration (concave part) with your finger to remove any gap.
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e) Remove the release paper of the double-sided tape.
f) Place the smallest water guard sheet (3.15in. (80mm) x 3.94in. (100mm)) so that its double-sided tape side comes to the farther side from you, and then place the separating point of the airbag sub harness at the center of the sheet.
NOTE:
DO NOT place the water guard sheet in a wrong direction. Make sure that the double-sided tape side is on the farther side from you.
g) Wrap the water guard sheet from the side without double-sided tape, and then seal with double-sided tape for temporary fixing.
h) Double-check the airbag sub harness is placed correctly on the sheet.
i) Fix the both ends of the water guard sheet with vinyl tape.
NOTE:
-Make sure that the water guard sheet is securely fixed.
-It is recommended you used a colored tape as it will be used to position the harness in the vehicle
j) Remove the release paper of the double-sided tape.
k) Place the biggest water guard sheet (5.91in. (150mm) x 5.91in. (150mm)) so that its double-sided tape side comes to the left side, and then place the link connector (Yellow color) as shown in the illustration.
NOTE:
Place the link connector so that its connecting part to instrument panel wire comes to the side with no double-sided tape of the water guard sheet.
l) Fold the water guard sheet so that its end is aligned with the end of the link connector.
m) Make sure that the both ends of the folded water guard sheet and the link connector are aligned, and then seal the water guard sheet with double-sided tape.
n) Set a cable tie at center of the convex part of the link connector and fix the water guard sheet and link connector securely.
NOTE:
• A gap between the cable tie and the water guard sheet may cause the tie eventually be loosened and released. Make sure that the gap is reduced as much as possible.
• Make as little wrinkles as possible on the water guard sheet when installing it.
o) Cut off the excess of the cable tie.
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p) Remove the release paper of the double-sided tape.
q) Place the water guard sheet (4.72in. (120mm) x 5.91in. (150mm)) so that its double-sided tape side comes to the farther side from you, and then place the module (Black color) as shown in the illustration.
r) Wrap the water guard sheet around so that it does not wrinkle.
s) Make sure that the water guard sheet is not wrinkled and seal the water guard sheet with double-sided tape.
t) Set a cable tie at center of the module and fix the water guard sheet and module securely.
NOTE:
• A gap between the cable tie and the water guard sheet may cause the tie eventually be loosened and released. Make sure that the gap is reduced as much as possible.
• Make as little wrinkles as possible on the water guard sheet when installing it.
u) Cut off the excess of the cable tie.
INTERMEDIATE INSPECTION (BY ANOTHER WORKER)
Confirm airbag sub harness is in proper condition
– Check the cable tie is fixed properly and if it is installed loose (big gap), tighten up the cable tie until fixed tightly (small gap).
– Confirm that the cable tie is installed at the center of the convex part of the link connector.
– Confirm that the cable tie is installed at the center of the module.
– Confirm that the water guard sheet is not flipped up.
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5. INSTALL AIRBAG SUB HARNESS
Click the play button to watch a video on how to install the airbag sub harness
NOTE: The video may take several minutes to load depending on internet connection.
The procedure shown in these technical instructions is for 2012MY AVALON only. DO NOT use it for other vehicle models.
a) Disengage the clamp.
b) Separate the harness of the connector (30P) from the clamp.
c) Using a screwdriver, disengage the 2 claws to release the retainer from the connector holder of the airbag sensor.
NOTE:
DO NOT remove the retainer from the connector holder completely. If removed, temporarily install it to the connector holder.
d) Using a screwdriver, disengage the claw and remove the connector (30P) from the connector holder.
e) Connect the connector (30P) of airbag sub harness to the connector holder of the airbag sensor and lock the retainer securely.
• DO NOT twist the airbag sub harness forcibly as it may be damaged.
• DO NOT touch the terminals of the link connector. Also, make sure that no foreign matter enters the terminals of the link connector.
• Securely lock the retainer.
f) Connect the connector holder to the airbag sensor.
g) Lock the lever securely.
• Securely lock the lever.
• Make sure that the water guard sheet of the airbag sensor is not flipped up or caught.
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h) Install the airbag sub harness into the clamp.
NOTE:
DO NOT clamp removed connector (30P) of the instrument panel wire again.
i) Engage the clamp.
j) Install the connector (30P) of the instrument panel wire to the provided connector holder and lock the retainer securely.
• Make sure that the connector (30P) is securely installed to the connector holder (provided).
• Securely lock the retainer.
• DO NOT lock the lever yet.
k) Flip up the water guard sheet of the link connector and connect the connector (30P) with connector holder (provided).
l) Lock the lever securely.
• Securely lock the lever.
• Make sure that the water guard sheet is not flipped up and not pinched.
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Check each connector is securely connected.
(The retainers of connector holders are also securely installed)
m) Align the cable tie of the link connector and the cable tie of the module.
NOTE:
Be sure that place so that the part not protected by the water guard sheets are on the underside of the vehicle.
n) Align the vinyl tape fixing the smallest water guard sheet (link connector and module side) with the cable ties.
o) Using a cable tie, fix the airbag sub harness as shown in the illustration.
p) Cut off the excess of the cable tie.
q) Link 2 cable ties.
r) Pass a cable tie between the clamps, and under the instrument panel wire (covered part).
Be careful not to include the uncovered part of the instrument panel wire.
s) Fix the link connector, module and harness as shown in the illustration.
NOTE:
Be sure to fix the link connector at around the center of convex part, as the cable tie may come off.
t) Cut off the excess of the cable tie.
if equipped:
u) Make sure that the distance between the link connector and the cabin oscillator (front) is 0.669 in. (17mm) or more, otherwise the smart key may not function properly.
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INTERMEDIATE INSPECTION (BY ANOTHER WORKER)
Confirm airbag sub harness is installed in proper condition
– Check each water guard sheet is not flipped up.
– Check each cable tie is fixed at its proper position.
– Check the cable tie is fixed properly and if it is installed loose, tighten up the cable tie. And then cut off the excess of the cable tie.
6. Post Repair Quality Checksheet
a. Login to the website below to complete the Post Repair Quality Checksheet
URL: https://toyota-trw.imagespm.info/
Login Credentials
Username: Dealer code
Password (1st time login): XXXXX
If you have any issues with the website contact Quality_Compliance@toyota.com for assistance.
b. Enter the following information into the site
Technician Name
Spin ID
Select your current Toyota certification
c. Enter the VIN into the website
d. Upload a picture of the completed wire harness installation as instructed on the website.
The picture you take MUST MATCH the angle of image shown below
Example picture
e. Record the warranty authorization number and provide it to the warranty administrator for claim filing.
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7. RESTORE THE VEHICLE
Click the link below to access TIS for instructions
SUPPLEMENTAL RESTRAINT SYSTEMS: CENTER AIRBAG SENSOR ASSEMBLY: INSTALLATION
(Doc ID: RM000000UWS06WX)
–
Be careful not to pinch the airbag sub harness when installing the console box.
8. INSPECT SRS WARNING LIGHT
a) Check that the airbag warning light lights when the power switch is turned on.
b) Check that the airbag warning light goes off approximately 6 seconds after turning on of the ignition switch.
NOTE:
If the airbag warning light remains on, it is likely to be caused by connection failure of the airbag connector.
◄ VERIFY REPAIR QUALITY ►
– Confirm there is no SRS light on
– Confirm center console has been properly installed and that no large gaps in trim are present
– Confirm you have completed the Repair Quality Checksheet and that the image you uploaded was correct.
If you have any questions regarding this Safety Recall, please contact your regional representative.
APPENDIX
A. CAMPAIGN DESIGNATION DECODER
1919 = 201920 = 202021 = 202122 = 202223 = 2023Etc…Year Campaignis Launched19TA01TT = ToyotaL = LexusVehicle MakeAA = Safety Recall RemedyB = Safety Recall InterimC = Special Service CampaignD = Limited Service CampaignE = Customer Support ProgramF = Emissions Recall(May use other characters in unique cases)Field Action Category and Phase0101 = 1st Field Action of the year02 = 2nd Field Action of the year03 = 3rd Field Action of the year(The sequence is unique for each Field Action category)(May use other characters in unique cases)Field Action Sequence
Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

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